Numerical calculation of residual stress development of multi-pass gas metal arc welding

Abstract In various applications, welding-induced residual stresses have a substantial impact on the integrity of welded constructions. Tensile residual stress can promote stress-corrosion cracking, brittle fracture, and reduces the fatigue life in service, as well as influences component design due to critical stress concentrations within the component. In the present paper, a six bead multi-pass gas metal arc weld of 20 mm thick structural steel S355J2+N is experimentally and numerically investigated. The studies include transient 2D and 3D numerical calculations which consider temperature-dependent material properties, phase transformations, “thermal” tempering, transformation plasticity, volume change due to phase transformation, an elastic–plastic material model, and isotropic strain hardening. The experimentally determined and calculated residual stresses are in a good agreement. Furthermore, the influence of the preheat and interpass temperature on welding-induced residual stresses is shown in the present investigation.

[1]  D. P. Koistinen,et al.  A general equation prescribing the extent of the austenite-martensite transformation in pure iron-carbon alloys and plain carbon steels , 1959 .

[2]  P. Michaleris,et al.  Effects of thermal transport in computation of welding residual stress and distortion , 2011 .

[3]  H. Bhadeshia,et al.  Residual stress. Part 2 – Nature and origins , 2001 .

[4]  Hidekazu Murakawa,et al.  Finite element analysis of temperature field, microstructure and residual stress in multi-pass butt-welded 2.25Cr–1Mo steel pipes , 2008 .

[5]  P. Michaleris Modelling welding residual stress and distortion: current and future research trends , 2011 .

[6]  J. Devaux,et al.  Mathematical modelling of transformation plasticity in steels I: Case of ideal-plastic phases , 1989 .

[7]  S. Suresh Babu,et al.  Effect of Continuous Cooling Transformation Variations on Numerical Calculation of Welding-Induced Residual Stresses Three continuous cooling transformation (CCT) diagrams for S355J2 steel were employed to study the effect of CCT variations on calculated residual stresses , 2010 .

[8]  J. Devaux,et al.  A theoretical and numerical approach to the plastic behaviour of steels during phase transformations—II. Study of classical plasticity for ideal-plastic phases , 1986 .

[9]  J. Goldak,et al.  A new finite element model for welding heat sources , 1984 .

[10]  J.Arnold Free,et al.  Predicting residual stresses in multi-pass weldments with the finite element method☆☆☆ , 1989 .

[11]  Jean-Baptiste Leblond,et al.  A new kinetic model for anisothermal metallurgical transformations in steels including effect of austenite grain size , 1984 .

[12]  A. De,et al.  A perspective on residual stresses in welding , 2011 .

[13]  J. Hildebrand Numerische Schweißsimulation - Bestimmung von Temperatur, Gefüge und Eigenspannung an Schweißverbindungen aus Stahl- und Glaswerkstoffen , 2008 .

[14]  T. Kannengiesser,et al.  Effects of the Load History on the Residual Stress Distribution in Welded Components , 2006 .

[15]  Mats Näsström,et al.  Simulation of multipass welding of a thick plate , 1999 .

[16]  R. B. Stonesifer,et al.  Computation of Residual Stresses due to Multipass Welds in Piping Systems , 1979 .

[17]  J. Devaux,et al.  A theoretical and numerical approach to the plastic behaviour of steels during phase transformations—I. Derivation of general relations , 1986 .